ML19309C564

App 5D to TMI-1 PSAR, Qc. Includes Revisions 1-11

ML19309C564
Person / Time
Site:	Three Mile Island
Issue date:	05/01/1967
From:	JERSEY CENTRAL POWER & LIGHT CO., METROPOLITAN EDISON CO.
To:
References
NUDOCS 8004080793
Download: ML19309C564 (8)

Text

APPENDIX 5D O QUALITY CONTROL 1 GENERAL ORGANIZATION Final responsibility for establishing quality control precedures and enforcing such procedures belongs to the Metropolitan Edison Company.

Met-Ed has assigned a Project Manager whose duties will include co-ordination and direction of all quality control measures. To carry out this responsibility in the field, Met-Ed vill assign a permanent field representative to monitor inspection procedures and other quality control measures carried out by the constructor. In addition, Met-Ed is developing an organization which vill monitor quality control =easures in the fabricators' shops and the field, and vill also audit all records.

Met-Ed vill also assign responsibilities for miclity control functions to the following organizations.

1.1 BABCOCK & WILCOX As contractor to the Met-Ed Co., B&W is responsible for developing quality control procedures and ensurin6 such procedures are observed for the shop fabrication of the nuclear components in their scope of supply. B&W will also develop or review field installation procedures for all such components.

B&W vill maintain technical representative (s) at the site as required by the Met-Ed Co.

1.2 GILBERT ASSOCIATES, INC.

As censultant to the Met-Ed Co., Gilbert Associates is responsible for developing quality control procedures for all elements of construction, excluding the nuclear ec=ponents in the B&W scope of supply. This includes the development of detailed specifications, testing procedures, and sur-veillance of tests as required to ensure that construction is completed so as to meet the intent of the design. All test reports, including mill chemical and physical reports on steel, cement chemical analyses, velding procedures, and qualifications vill be reviewed by Gilbert Associates to ensure specification ecmpliance. In addition Gilbert Asacciates vill main-tain at the job site an engineer as required by the Met-Ed Co. The engineer vill be familiar with the design of the Class I structures and qualified to interpret drawings and specifications for this work. The engineer will, through the Met-Ed representative, terminate work unless it meet; the intent of the design. The prime function of the engineer will be to monitor the detailed inspection and other quality control procedures of the constructor.

1.3 UNITED ENGINEERS AND CONSTRUCTORS As contractor to the Met-Ed Co., UE&C is responsible for all field quality control measures and all shop quality control =easures for equipment and materials other than that supplied by B&W. This includes acceptance of materials and verkmanship by subcentractors and the supply of all detailed p)

L inspection except that supplied by the testing agencies. UE&C vill =aintain 800408079D 5D-1 (Revised 10-2-67) 0003 006

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a quality control file for the entire project for all work except that cov-ered by 3&W scope of supply and will present this file to the Met-Ed Co. at the ccmpletion of work.

l.h INDEPDTDENT TESTING AGDICY For all soils and concrete work and velding, an independent testing agency /

agencies vill be retained by the construction manager, UE&C, to perform all field inspections and tests. These personnel win check earth back-tilling and vill maintain field operation surveillance of the concrete batch plant and job site concrete activities. They will have direct emunication with the construction manager, by passing the job superin-tendent if such is required to correct construction deficiencies. In addition, a separate organization or agency will be maintained by Met-Ed y to monitor and audit all inspection activities and records. This effort vill be in addition to that provided by the field representatives of Met-Ed and the designer.

2 MATERIALS STANDARDS 2.1 CONCRETE The Technical Specifications for structural concrete vill require the followin6 quality control measures:

2.1.1 QUALITY CONTROL

a. PRELIMINARY TESTS ,

The Owner vill obtain the services of a Testing Laboratory which j vill, prior to the Contractor ccamencing concrete work, make '

preliminary determinations of controlled mixes , using the insterials proposed and consistencies suitable for the work, in order to determine the mix proportions necessary to produce concrete con-forming to the type and strength requirements called for herein l or on the drawin6s. Aggregates shall be tested in accordance with j the latest editions of the following ASTM Specifications: C29, Cho, C12, C128, and Cl36. Compression tests shall conforn to ASS 4 Spec-ifications C39-6h and C192-65. The Contractor shall submit to the i Testing Laboratory a sufficient time before concrete work will commence all concrete ingredients required by the Testing Laboratory for these preliminary tests.

The proportions for the concrete mixes vill be determined by Method i 2 of Section 309 of ACI 301 and as herein specified.

J The Engineer shall have the right to make adjustments in concrete proportions if necessary to meet the requirements of these specifi-cations, p[, ' I;[' . :

5D-2 (Revised 10-2-67) 0003 007 l

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In the event the Contractor furnished reliable test records of O concrete made with materials from the same sources and of the same quality in connection with current vork, then all or a part of the strength tests specified herein may be vaived by the Engineer, subject, however, to any provisions to the contrary of building codes or ordinances of the governing authority,

b. FIELD TESTS During concrete operations, the Testing Laboratory will have an inspector at the batch plant who will certify the mixed proportions of each batch delivered to the site and sample and test periodicall all concrete ingredients. Another inspector (s) at the constructic site vill inspect reinforcing and form placements, take slump tests j - make test cylinders, check air content, and record weather conditic O

O 0003 008 i

5D 2a (Revised 10-2-67)

Except as noted hereinafter, test cylinders vill be molded, cured, capped, and tested in accordance with ACI 301 except that one of the three cylinders vill be tested at three days and the remaining tvo at 28 days. For the Reactor Building a set of four cylinders vill be made for each 50 cubic yards or fraction thereof placed in any day.

One cylinder shall be tested at three days , another cylinder at seven days , and the remaining two cylinders at 28 days. Slump tests vill be =ade at randcm with a =inimum of one test for each 10 cubic yards of concrete placed, also slump tests vill be made on the concrete batch used for test cylinders.

In the event that concrete is poured during freezing weather or that a freeze is expected during the curing period, an additional cylindez vill be made for each set and be cured under the same conditions as the part of the structure Vaich it represents.

c. TEST EVALUATION The evaluation of test results vill be in accordance with Chapter 17 of ACI 301. Sufficient tests vill be conducted to provide an evalua-tion of concrete strength in accordance with this Specification.

d. DEFICIENT CONCRETE Whenever it appears that tests of the laboratory cured cylinders fail to meet the requirements set forth in this Specification, the Enginee O and/or Testing Laboratory shall have the right to:

1. Order changes to the proportions of the mix to increase the strength.

2. Require additional tests of specimens cured entirely under field conditions.

3. Order changes to improve procedures for protecting and curing the concrete.

h. Require additional tests in accordance with " Methods of Obtainine and Testing Drilled Cores and Saved Beams of Concrete," ASTM Ch2-ch.

2.2 REINFORCING STEEL Testing and inspection of all reinforcing steel vill be perfor ned at the mill to ASTM requirements. Certified mill reports vill be submitted to the Engi-neer, Gilbert Associates , Inc. , for review and approval. Each bar is branded in the deforming process to carry identification as to the manufacturer, size, type, and yield strength.

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0003 00$

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Example:

O B - Bethlehem

• 18 - Size 18S N - New billet steel Blank - A-15 and A h08 steel 6 - A-*32 60,000 psi yield 7 - A-h31 75,000 psi yield Because of the identification system and the large quantity , the material vill be kept separated in the fabricator's yard. In additien, when loaded for mill shipment, all bars vill be properly separated and tagged with the

=anufacturer's identification number.

Visual inspection of the bars vill b.e made in the field fox inclusions. The bars vill be randanly sampled in the field and tested to destruction to check specification complianct.

2.3 CADWELD SPLICES Tension splices for bar sizes larger than #11 vill be made with a Cadweld splic2 which vill develop the ultimate strength of the bar. To ensure the integrity of the Cadweld splice the quality control procedure vill provide for a random sampling of splices in the field. The selected splices will be removed and tested to destruction.

A sampling of at least sixteen (16) splices will be laitially tested to destruction to develop an average (2) and standard deviation (&). Sufficient samples vill, therefore, be tested to provide 99 per cent confidence level that 95 per cent of the splices meet the specificetion requirements. As additional data beccmes available, the average (f) and standard deniation (5-) vill be updated and the quantity of samples revised accordingly.

The distribution established on this basis vill permit the development of the lover li=it belev which no test data should fall. If the result of any test falls below this limit, the subseq, tent or previous splice vill be sampled.

If this result is above the lever limit, the process is considered to be in control. If this result is again belev the lover limit, the process average must have changed and an engineering investigation vill be required to deter-mine the cause of the excess variation and re-establish control. The work of each splicing crev vill be individually sampled.

2.h REACTOR BUILDING The Technical Specifications for the Reactor Building liner require that steel plate for the main shell including the dcme, cylindrical valls, and base shall conform to " Tentative Specification for Structural Steel," ASTM A36-63T or to ASTM 283

Quality control measures required by this standard specification include the '

following:

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,1, 0003 110 ED h (Revised 1-d-68)

O "Two tension and two bend tests shall be made frem each heat, unless the finished material from a heat is less than 30 tons , then ene tension test and one bend test vill be sufficient. If, hcvever, =aterial from one heat differs 3/8 in. or scre in thickness , one tension test and one bend test shall be made frem both the thickest and the thinnest material rolled, regardless of the weight represented."

The Technical Specifications for the Reactor Building liner further require that, "The materials for penetrations including the personnel and equipment access hatches as well as the mechanical and electrical penetrations shall conform with the requirements of the ASME Nuclear Vessels Code for Class "B" vessels... All materials for penetrations shell exhibit impact properties as required for Class "B" vessels . . ."

The =aterial for the penetrations vill,as a minimum requirement, conform to "Temtative Specification for Carbon-Silicon Steel Plates of Intermediate Tensile Ranges for Fusion-Welded Boilers ana Other Prr.asure Vessels" ,

ASTM A201-61T, Grade 3 Firebox, modified to " Standard Specification for l Steel Plates for Pressure Vessels for Service at Lov Temperature'* ASTM j A300-58. I i

quality control measures required for ASTM A201 include the following:  !

"Two tension tests , one bend test , and one hemcgeneity test shall be made from each firebov, steel plate as rolled. One tension test and one bend test shall be made fran each flange steel plate as rolled."

The Technical Specifications for the Reactor Building liner further require

() the following quality control =easures for velding:

The qualification of welding procedures and welders shall be in accordance i with Section IX " Welding Qualifications" of the ASME Boiler and Pressure j Vessel Code... Centractor shall submit velding procedures to the Engineer for reviev...

Longitudinal and circunferential velded joints within the main shell, the velded joint connecting the dome to the cylindrical side valls , and any velded joints within the deme shall be inspected by the liquid penetrant method and spot radiography.. . All penetrations . . . shall be examined in accordance with the requirements of the ASME Nuclear Ves=els Code for Class "B" Vessels . All other shop fabricated components including the reinforce-ment about openings shall be fully radiographed. All non-radiographable joint details shall be examined by the liquid penetrant method.

Full radiography shall be in accordance with the precedures and governed by the acceptability standards of Parsgraph N-62k of the ASME Nuclear Vessels Code. Spot radiography shall be in accordance with the procedures and governed by the acceptability standards of Paragraph UW-52 of the ASME Unfired Pressure Vessels Code except that 2 percent of the velds shall be spot radiographed.

Methods for liquid penetrant examination shall be in accordance with Appendix (s VIII of the ASME Unfired Pressure Vessels Code except that 20 percent of the

(,,) welds shall be tested by liquid penetrant.

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9!' 0003 011 5D-5 (Revised 1-8-68)

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• In order to ensure that the penetrations as well as all veld connections 9-between penetration sleeves and plate are leak-tight, the Technical Spec-ifications for the Reactor Building liner require that all velds "shall be es amined by detecting leaks at 63.3 psig test pressure using a soap bubble test or a mixture of air and freon.. . and 100.per cent of detectable leaks arres ted. " These tests are all preliminary to the perfomance of the inte-grated leak rate test which will ensure that the containment leak rate is no .g;reater than 0.2 per cent of the contained volune in 2h hours at 55 psig.

25 LINER WELDING RADIOGRAh.

All accessible veld seems on the liner vill be spot radicgraphed except for penetrations which vill be fully radiographed. Spot radiography will be performed in accordance with Section (N-52 of the ASME Unfired Pressure Vessels Ccle except that 2 percent of the velds vill be spot radiographed.

DEL m p 2.6 PPESTRZSSING TENDONS The prestressing and tendons for the containment vill be inspected by both the supplier and representatives of the Owner.

If the BBRV system is selected for use, the Supplier vill do the following:

2. Obtain certified =111 test reports of chemical r.nd physical properties of each reel of wire and submit them to tne Ovner. Material must meet requirements of ASTM Ah21-65, Type BA.

b. Cut coupons frem each end of each reel of vire, fom buttonheads on the specimens and test them in tension to destruction. These tests vill ensure that the wire ruptures before failure of the buttochead and that the wire develops a ninimum ulti= ate tensile stren6th of 2h0,000 psi. Coupons , and the coils they represent, not meeting the requirec:ents vill be rejected. Records vill be maintained for each coupon test and for the tendons in which each coil of wire is used. These records vill be submitted to the Owner.

c. Cut vires within ! 3/32 inch of the specified length of less than 50 feet and within ! 1/8 inch if greater than 50 feet,

d. Check each buttonhead by visual examination for general appearance and splits. Splits parallel to the tendon axis or inclined no more

, than 20 degrees are acceptable if their total width does net exceed

( 060 inch.

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A =aximu= of two splits inclined between 20 degrees and h5 degrees {

can be accepted providing they do not lie in the same plane. The l total vidth of cracks cannot exceed 0.06 in. 1 l

Iif 'M 0003 012 l 5D-6 (Revised 1-6-68)

p Splits inclined more than h5 degrees are not acceptable. .

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e. Ten per cent of the buttonheads , selected by randcm, vill be checked dimensionally. Diameter =ust not be less than .372 inen nor more than .388 inch. Head length must not be less than .252 inch nor more than .272 inch. The buttenhead must have a bearing surface on all sides.

The Owner's quality control representative / representatives will do the following:

a. Submit certified mill test reports to the Engineer, Gilbert Associates , Inc. for their review and ccm: ment.

b. Monitor the shop procedures and inspection by the Supplier.

c. Inspect each tendon at the Supplier's shop before shipment to insure conformance to specirications and proper preparation for shipment.

If a system utilizing vire strands is selected, an equivalent procedure of quality control measures will be developed.

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. 0003 013 5D-T l

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